Roof system

ABSTRACT

A roofing system provides a stronger bond than conventional roof systems to withstand greater uplift pressures in hurricane force winds, while also providing a sound fire rating. The system includes a non-corrosive metal blocking structure, including a perimeter edge closure that has an anchoring flange for attachment to the roof deck, a parallel upper flange and an intermediate flange extending perpendicularly between the upper and lower flanges. The system further includes lightweight insulating concrete applied to the roof deck and filled between the upper and lower flanges of the edge closure, an inter-ply sheet applied by torch or self-adhesive directly to the insulating lightweight concrete, and a torch applied cap membrane over the inter-ply sheet. Direct attachment of the inter-ply sheet to the lightweight insulating concrete without the use of hardware fasteners preserves the integrity of the underlying lightweight insulating concrete for future re-roofing.

This application is based on provisional patent application Ser. No. 60/744,120 filed on Feb. 16, 2006.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to roofing systems, and, more particularly, to roofing systems that use lightweight insulating concrete with an overlying inter-ply sheet and cap membrane on flat roof areas.

2. Discussion of the Related Art

Currently, the traditional roof system that is used on flat roof areas consists of wood blocking at the perimeter edge of the roof, a lightweight insulating concrete deck, and a base sheet mechanically fastened to the underlying lightweight insulating concrete with the use of fasteners and washers. Once the base sheet has been mechanically attached to the lightweight insulating concrete, a two ply modified roof system is applied to the base sheet. The two ply system uses an inter-ply sheet and a cap membrane and is applied using a torch heat weld or a cold applied adhesive to adhere the inter-ply sheet and cap membrane over the base sheet.

This currently used roof system, as described above, has several problems. In particular, wood, by its nature, is subject to rotting and deterioration. Also, wood blocking is a flammable product and, thus, has an inferior fire rating. In addition, the use of mechanical fasteners to attach the base sheet creates holes in the light concrete. This results in weakening of the underlying lightweight insulating concrete deck. Moreover, a re-roof requires removal of the base sheet and fasteners and application of a new base sheet and fasteners to the original lightweight insulating concrete deck. This further compromises the strength of the lightweight concrete by adding additional holes to the lightweight concrete as a result of attachment of the new base sheet fasteners.

OBJECTS AND ADVANTAGES OF THE INVENTION

Considering the foregoing, it is a primary object of the present invention to provide an improved roof system that replaces wood blocking with a non-corrosive metal blocking system to provide for increased uplift strength and a sound fire rating, while also eliminating the problem of deterioration of the blocking assembly.

It is a further object of the present invention to provide an improved roof system that uses a non-corrosive metal blocking system and which eliminates use of a base sheet and fasteners on the lightweight insulating concrete deck, thereby preserving the strength of the underlying lightweight insulating concrete for future re-roofs.

It is still a further object of the present invention to provide an improved roof system that utilizes an inter-ply sheet that is torch applied or self-adhered directly to the underlying lightweight concrete to provide a stronger bond than conventional systems that use a base sheet and fastener system.

It is still a further object of the present invention to provide an improved roof system for use on flat roof areas that uses non-corrosive metal blocking and an inter-ply sheet that is torched applied or self-adhered directly to the underlying lightweight insulating concrete deck, and wherein the roof system is structured to withstand greater uplift pressures than existing conventional roof systems in hurricane force winds.

These and other objects of the present invention are more readily apparent with reference to the detailed description and drawings.

SUMMARY OF THE INVENTION

The present invention is directed to a roofing system that is structured to provide a stronger bond than conventional roof systems to thereby withstand greater uplift pressures in hurricane force winds, while also providing a sound fire rating. The system includes a non-corrosive metal blocking structure, including a perimeter edge closure that has an anchoring flange for attachment to the roof deck, a parallel upper flange and an intermediate flange extending perpendicularly between the upper and lower flanges. The system further includes lightweight insulating concrete applied to the roof deck and filled between the upper and lower flanges of the edge closure, an inter-ply sheet applied by torch or self-adhesive directly to the insulating lightweight concrete, and a torch applied cap membrane over the inter-ply sheet. Direct attachment of the inter-ply to the lightweight insulating concrete without the use of hardware fasteners preserves the integrity of the underlying lightweight insulating concrete for future re-roofing.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view showing one embodiment of a non-corrosive metal blocking structure used in the roof system of the present invention; and

FIG. 2 is an isolated perspective view, shown in cross-section, illustrating the installed arrangement of the component elements of the roof system of the present invention.

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The roof system of the present invention is shown in FIG. 2 and is generally indicated as 10.

Referring to FIG. 1, a non-corrosive metal blocking structure is used in the roof system of the present invention and replaces wood blocking of conventional roof systems. In this particular embodiment, the non-corrosive metal blocking structure is a perimeter edge closure 20 that includes an anchoring flange 22 that attaches to the roof deck 100 using industry standards fasteners. The perimeter edge closure 20 also includes and upper flange 24 extending in spaced, parallel relation above the anchoring flange 22, forming a gap or area of depth therebetween. An intermediate flange 26 extends perpendicularly between the upper flange and the anchoring flange along the outer perimeter of the roof.

Referring now to FIG. 2, the entire assembled components of the roof system 10 are shown in a cross-sectional perspective view. In this particular example, the underlying roof deck 100 is a metal deck having flutes 110. The flutes are filled with lightweight insulating concrete. A slurry coat of lightweight insulating concrete 30 continues above the roof deck 100. The lightweight insulating concrete deck may further include an EPS Holly board insulation layer 32, and a top coat 36 of lightweight insulating concrete. Combined, the slurry coat 30, EPS Holly board insulation layer 32 and top coat 36 form the lightweight insulating concrete deck which is filled within the gap defined between the anchoring flange 22 and upper flange 24 of the perimeter edge closure 20.

Next, an inter-ply sheet 40 is applied to the top coat 36 of lightweight insulating concrete by torch weld or self-adhesive effectively to attach the inter-ply sheet 40 to the insulating lightweight concrete deck. Thereafter, a granulated cap membrane 50 is torch applied to the inter-ply sheet 40.

While the present invention has been shown and described in accordance with a preferred and practical embodiment thereof, it is recognized that departures from the instant disclosure are contemplated within the spirit and scope of the present invention. 

1. A roof system for installation on a roof deck of a building structure comprising: a slurry coat of lightweight insulating concrete applied on a top surface of the roof deck; a layer of insulation applied on top of said slurry coat; a top coat of lightweight insulating concrete applied over said layer of insulation; an inter-ply sheet applied and bonded to said top coat; and a cap membrane applied on top of said inter-ply sheet and bonded to said inter-ply sheet.
 2. The roof system as recited in claim 1 wherein said layer of insulation is EPS Holly board.
 3. The roof system as recited in claim 1 wherein said inter-ply sheet is bonded to said top coat by torch weld.
 4. The roof system as recited in claim 1 wherein said inter-ply sheet is bonded to said top coat with an adhesive.
 5. The roof system as recited in claim 1 wherein said cap membrane is bonded to said inter-ply sheet by torch weld.
 6. The roof system as recited in claim 1 further comprising a metal edge closure attached to the roof deck and extending about a perimeter of the roof deck.
 7. The roof system as recited in claim 6 wherein said metal edge closure comprises: an anchoring flange structured and disposed for attachment to the roof deck; an upper flange extending parallel to said anchoring flange and spaced above said anchoring flange; an intermediate flange extending perpendicularly between said anchoring flange and said upper flange; and said anchoring flange and said upper flange being spaced apart to form a gap for receipt of the slurry coat, the layer of insulation and the top coat between said anchoring flange and said upper flange.
 8. A roof system for installation on a roof deck of a building structure comprising: a metal edge closure including an anchoring flange structured and disposed for attachment to the roof deck along a perimeter of the roof deck, an upper flange extending in spaced relation above the anchoring flange to form a gap between the anchoring flange and the upper flange, and an intermediate flange extending perpendicularly between said anchoring flange and said upper flange; a lightweight insulating concrete deck applied on a top surface of the roof deck and within the gap between the anchoring flange and the upper flange of the metal edge closure; an inter-ply sheet applied to the lightweight insulating concrete deck and bonded to a top surface of the lightweight insulating concrete deck; and a cap membrane applied on top of the inter-ply sheet and bonded to the inter-ply sheet.
 9. The roof system as recited in claim 8 wherein the lightweight insulating concrete deck comprises: a slurry coat of lightweight insulating concrete applied on a top surface of the roof deck; a layer of insulation applied on top of said slurry coat; and a top coat of lightweight insulating concrete applied over said layer of insulation.
 10. The roof system as recited in claim 9 wherein said layer of insulation is EPS Holly board.
 11. The roof system as recited in claim 9 wherein said inter-ply sheet is bonded to the top coat by torch weld.
 12. The roof system as recited in claim 9 wherein said inter-ply sheet is bonded to said top coat with an adhesive.
 13. The roof system as recited in claim 9 wherein said cap membrane is bonded to the inter-ply sheet by torch weld.
 14. The roof system as recited in claim 8 wherein the roof deck is a metal deck having flutes. 